PREPARATION OF ALKYL KETENE DIMERS

Description

FIELD OF THE INVENTION.

[0001] The embodiments of the present invention relate to a process for the preparation of alkyl ketene dimers for paper applications.

BACKGROUND OF THE INVENTION

[0002] Alkyl ketene dimers (AKD) are typically utilized as sizing products in the pulp and paper industry. To this end AKDs, a waxy, water-insoluble substance, are usually added usually in the form of aqueous dispersions comprising cationic starch or cationic synthetic polymers as dispersing agents in the paper making process.

[0003] A common procedure used in the preparation of AKD includes the addition of fatty acid chlorides (FAC) (typically having structures of the general formula CH₃(CH₂)_nCOCl where n is an integer ranging from 8 to 20) to a heated mixture of triethylamine (TEA) and an inert solvent(s). Typical processes require the presence of the inert solvent to dilute the above-described slurry to ensure good mixing and product separation. In the absence of the inert solvent, the reaction viscosity of the FAC amine mixture increases as a TEA-Cl salt by-product forms. It is the formation of this by-product in the FAC amine mixture which makes effective mixing of the reactants and removal of the final AKD product difficult to effectively achieve. Examples of typical solvents utilized in the preparation of AKD are propylene dichloride and toluene.

[0004] Attempts have been made in the industry to reduce or remove the solvents from the AKD formation process whereby either the dilution solvent has been replaced by an excess amount of tertiary amine or through the use of rigorous distillation. Typically, the resultant AKD is isolated by filtering the solvent/AKD solution where the remaining solvent in the AKD fraction is reduced via distillation. However, such processes, including those utilizing distillation steps, remain problematic because trace amounts of solvent remain in the final product.

[0005] US Patent No. 5,672,721 teaches the production of AKD with low amounts of solvent by using a water immiscible inert solvent followed by a two-stage distillation step followed by the addition of water or steam

[0006] US Patent No. 5,344,943 teaches a process for the preparation of long-chain alkyl ketene dimers in the absence of additional organic solvents through the use of a molar excess of triethyl amine to fatty acid chloride. The process requires the use of intensive mixing to generate high shear rates which controls the viscosity of the reaction mixture. This process is difficult to practice at the larger scales needed for commercial production of AKD products.

[0007] US Patent No. 5,399,774 teaches the use of tertiary amines as both a reactant and as a diluent. In this use, at least 1.15 moles of amine is used per mole of fatty acid chloride to make AKD. Amines useful in the process may be either monoamines or diamines. The process described teaches stripping tertiary amine hydrogen halide crystals formed in the production of AKD with an acid. Care must be taken when using the acid so as not to hydrolyze the AKD with the acid

[0008] US Patent No. 5,502,218 teaches the solventless production of alkyl ketene dimers which uses pre-prepared crystals of tertiaryamine hydrogen halide as a diluent in the production of AKD products, where the tertiary amines are used in a stoichiometric to molar excess amount relative to the amount of fatty acid chloride used. WO 03/097566 describes a method for producing dialkyl diketenes from long-chain fatty acid chlorides and tertiary amines using a catalys such as 1,4-diazabicyclo (2.2.2) octane as a catalyst for dimerizing monomeric alkyl ketenes.

[0009] There still remains a need to have a process for the manufacture of AKD products which is able to be performed on a commercial scale and which results in a final AKD product which has a sufficiently low level of residual solvent.

[0010] The use of solvents in the preparation of AKD creates a problem due to environmental concerns regarding the presence of residual halogenated and/or low boiling solvents in the final AKD product.

[0011] These residual solvents pose a problem for the papermaking industry by requiring papermills to make the necessary accommodations for the solvent as it escapes In the exhaust from during drying operation. Also, solvent will be present in effluent produced by the papermilis.

[0012] Additionally, the residual solvent may be present in the cellulosic products containing the AKD product. The presence of these residual solvents may limit the end uses for these cellulosic products and make their use inappropriate for endproducts which are required to be essentially free of any residual solvents, such as for example for packaging for food contact.

[0013] Thus, a heretofore-unaddressed need exists in the industry to provide processes for the preparation of AKD without the addition of solvents which ultimately remain in detectable levels in the final AKD product and cellulosic products treated with AKD products.

SUMMARY OF THE INVENTION

[0014] The present invention relates to a process for the preparation of alkyl ketene dimers, comprising the steps in sequence of:

(a) charging a polyamine to a reaction vessel, and then heating the polyamine to a temperature ranging from 50°C to 70°C;

(b) charging a fatty acid chloride to the reaction vessel containing the polyamine over a time period ranging from 30-90 minutes, thereby forming a reaction mixture comprising an alkyl ketene dimer/amine salt

(c) adding an amount of water to the reaction mixture wherein an organic alkyl ketene dimer layer and an aqueous salt layer are formed;

(d) separating the organic alkyl ketene dimer layer and the aqueous salt layer,

wherein the polyamine used in the process is present in amounts ranging from 0.5 to less than 1.0 equivalents per mole equivalent of fatty acid.

DETAILED DESCRIPTION

[0015] The embodiments of the present invention describe a process for the preparation of alkyl ketene dimers (AKD), wherein a AKD product contains significantly low levels of residual solvent(s), the process comprising:

(a) charging a polyamine to a reaction vessel and heating the amine to a temperature ranging from 50°C to 70°C, preferably ranging from 50°C to 65°C, more preferably ranging from 55°C to 65°C, most preferably 65°C;

(b) charging a fatty acid chloride to the reaction vessel over a time period ranging from 30-90 minutes, preferably 35 to 40 minutes, most preferably 40 minutes, wherein the fatty acid chloride is used in amounts in excess of 1.0 molar equivalents relative to the amine, thereby forming a reaction mixture comprising an alkyl ketene dimer/amine salt;

(c) adding an effective amount of water to the reaction mixture to form an alkyl ketene dimer layer and an aqueous salt layer in the reaction mixture:

(d) optionally heating the reaction mixture to a temperature ranging from 90°C to 105°C; and

(e) separating the organic alkyl ketene dimer layer and the aqueous salt layer.

wherein the polyamine is present in amounts ranging from 0.5 to less than 1.0 equivalents per mole equivalent of fatty acid chloride, preferably ranging from 0.5 to 0.95equivalents, more preferably ranging from 0.6 to less than 0.95 equivalents.

[0016] The process for the preparation ot AKD may be performed in a batch, semi-batch or continuous manner.

[0017] While not wishing to be bound by theory, the following depicts a generalized mechanism for AKD formation of the present invention.

[0018] The embodiments of the present invention provide for the preparation of AKD through the use of tertiary polyamines, more particularly bi- and tri-cyclic tertiary amines and polar tertiary amine, wherein the process is performed with low levels or more particularly, in the absence of halogenated or volatile organic solvents.

[0019] In the embodiments of the present invention, the polyamine may be at least one of the polyamines that are tertiary cyclic amines which can be polycyclic straight-chain or branched.

[0020] Typically, the tertiary polycyclic amine may be a polycyclic tertiary amine comprising moieties containing polar functional groups. These amines are highly reactive due to their particular steric considerations and through chemical assistance available through the polar functionality.

[0021] Tertiary cyclic polyamines suitable for use with the embodiments of the present invention include those having the general structure:



        K = (CH₂)_z(C)_y(O)_p(CH₂)_n(N)_m

n = 0 to 1

n = 0 to 1

m = 0 to 1

z = 0 to 6

y = 0 to 1

p = 0 to 1

q = 0 to 1

wherein the values of n, m, z, y and q can be the same or different and the sum of the values of n, m, z, y and q is greater than 1 and wherein the amines contain one or more heteroatomic rings, each of which may contain two or more tertiary amines per ring, wherein these amines may also further contain one or both of a carbonyl unit or ether linkage, forming an ether, ester or acetate functionality within the moiety. The cyclic polar amines can act as both a reactive amine and a diluent for in the preparation of AKD.

[0022] The polyamines are utilized in the production of AKD because of the inherent basicity of the tertiary amine functionality while utilizing the additional amines present in the polyamine and the hydrocarbon backbones (per mole of material of the polyamine for improved reactivity and lower reaction viscosity of the reaction mixture comprising AKD and amine salt.

[0023] Typically, useful polyamines are of the structure R₁R₂R₃N, where R is an alkyl or alkenyl chain containing one or more repeating tertiary unit. R₁, R₂ and R₃ can be separate or connected forming one or two heteroatomic rings. While not wishing to be bound by theory the polyamine structures contain two alkyl "arms" on the reactive amines that are pinned back, thereby exposing a nitrogen lone pair of electrons, where the electrons are better suited to participate in the SN2 displacement of the FAC and formation of the AKD.

[0024] Preferred cyclic polyamines suitable for use with the embodiments of the present invention are those having the general structure:



        K = (CH₂)_z(C)_y(O)_p(CH₂)_n(N)_m

n = 0 to 1

m = 0 to 1

z = 0 to 6

y = 0 to 1

p = 0 to 1

q = 0 to 1

wherein the structures contain one or more heteroatomic rings, each of which may contain two or more tertiary amines per ring and wherein the values of m, n, z, y and q can be the same or different and the sum of the values of m, n, z, y and q is greater than zero. The cyclic polyamines can act as both a reactive amine and as a diluent for the reaction mixture comprising AKD and amine salt.

[0025] Non-limiting examples of preferred cyclic polyamines include 1,4-diazabicyclo[2.2.2]octane, hexamethyltetramine, 1,4-dimethyl piperazine and 4,4'-trimethylenebis(1-methyl-piperidine). Most preferably, the cyclic polyamine is 1,4-dimethyl piperazine.

[0026] Furthermore, the cyclic polyamines useful in the present invention must be in a liquid state at the operating temperature of the process for the preparation of AKD.

[0027] Typical straight-chain tertiary polyamines suitable for use in the embodiments of the present invention include those having the general structure:





        K = (CH₂)_z(C)_y(O)_p(CH₂)_n(N)_m

n = 0 to 1

m = 0 to 1

z = 0 to 6

y = 0 to 1

p = 0 to 1

q = 0 to 1

and where the typical branched -chain tertiary polyamines suitable for use in the embodiments of the present invention include those having the general structure





        K = (CH₂)_z(C)_y(O)_p(CH₂)_n(N)_m

n = 0 to 1

m = 0 to 1

z = 0 to 6

y = 0 to 1

p = 0 to 1

q = 0 to 1

where n, m, z, y and q may be the same or different values and the sum of n, m, z, y and q is greater than zero and where the structures contain two or more tertiary amines connected via an alkyl chain comprising one or more carbon units, which may also contain one or both of a carbonyl unit or ether linkage, forming ester, acetate or ether functionality within the moiety. The branched tertiary polyamines can act as both a reactive amine in the formation of AKD and as a diluent for the resultant AKD/amine salt reaction mixture.

[0028] Examples of suitable branched tertiary polyamines include, but are not limited to, N,N,N',N",N"',N"'-hexamethylethylenetetramine; N,N,N",N"-tetramethyl-1,6-hexanediamine; N,N,N',N"N"-pentamethyldiethylenetriamine; N,N,N",N"-tetramethyl-1,3-propanediamine; N,N,N",N"-tetraethylethylenediamine; N,N,N",N"-tetramethylethylenediamine and N,N,N",N"-tetramethylmethylenediamine. Preferred examples include N,N,N",N"-tetramethyl-1,6-hexanediamine; N,N,N',N"N"-pentamethyldiethylenetriamine; N,N,N",N"-tetramethyl-1,3-propanediamine; N,N,N",N"-tetraethylethylenediamine. The most preferred branched tertiary polyamines are N,N,N",N"-tetramethyl-1,6-hexanediamine and N,N,N',N"N"-pentamethyldiethylenetriamine.

[0029] Examples of suitable straight-chain tertiary polyamines include, but are not limited to 2,4-dimethyl-2,4-diazapentane, 2,5-dimethyl-2,5-diazahexane, 1,1'-(1,2-ethanediyl)bis[piperidine], N,N,N', N'-tetramethyl-1,2-diaminocyclohexane, 1,4-dimethyl-1,4-diazacyclohexane, diazabicyclo[2.2.2]octane, 2,6-dimethyl-2,6-diazaheptane, 2,7-dimethyl-2,7-diazaoctane, 2,7-dimethyl-2,7-diaza-4-octene, 2,7-dimethyl-2,7-diaza-4-octyne, 2,9-dimethyl-2,9-diazadecane, and 2,5,8,11-tetramethyl-2,5,8,11-tetraazadodecane.

[0030] With the straight-chain and branched tertiary polyamines, as with the cyclic amine moieties, the inherent basicity of the tertiary amine functionality, additional amines and hydrocarbon backbones (per mole of material) provide improved reactivity of the polyamine and lower reaction viscosity of the resultant AKD/amine salt reaction mixture. For example, branched tertiary polyamines like N,N,N",N"-tetramethyl-1,6-hexanediamine, the larger (e.g. C₆) hydrocarbon backbone allows the polyamine to acquire solvent-like properties, which assists in reducing the viscosity of the resultant AKD/amine salt reaction mixture.

[0031] Typical fatty acid chlorides suitable for use with the embodiments of the present invention are those having the general structure:

wherein R1 is C₇ to C₃₀ alkyl or C₇ to C₃₀ alkenyl and R2 is hydrogen or C₁ to C₈, more preferably R1 is C₁₀ to C₂₂ and R2 is hydrogen.

[0032] The fatty acid chloride can have up to 30 carbon atoms, suitably with from 12 to 22 carbon atoms and preferably with from 16 to 18 carbon atoms, or a mixture of such fatty acid chlorides. The fatty acid chloride can be either a saturated or unsaturated fatty acid chloride and as some examples can be chlorides of lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, palmitoleic acid, oleic acid etc. Chlorides of naturally occurring fatty acids such as those from coco and tallow can of course also be used. Stearic acid chloride is particularly preferred.

[0033] Once the reaction is complete an effective amount of water chilled to about 39°C to about 45°C is quickly charged to the reaction mixture, wherein the internal temperature of the reactor drops quickly below the freezing point of the AKD, thereby producing a waxy solid. Thus, the AKD is separated from the water layer which reduces the available surface area of the AKD to further protect the dimer from hydrolysis by limiting its contact with water. Reheating the reaction mixture to a temperature ranging from about 90°C to about 105°C melts the AKD, thereby facilitating a liquid/liquid separation of the AKD from residual amine salt present in the reaction mixture.

[0034] Optionally, as well as adding an effective amount of water to the reaction mixture, an acid treatment comprising treating the reaction mixture with aqueous inorganic acid may also be performed to aid in the removal of any residual amine from the reaction mixture. The concentration of the aqueous inorganic acid is dependent on the amount of polyamine remaining in the reaction mixture. One of the advantages of the present process is that since the polyamine is present in amounts ranging from about 0.5 to about less than 1.0 equivalents per mole equivalent of fatty acid chloride, treatment of the reaction mixture with the aqueous inorganic acid to remove excess polyamine is typically not necessary.

[0035] One advantage of the method of the present invention is the high dimer assays that are attainable in the reaction mixture. Through the use of the method of the present invention, almost ketene dimer assays of greater than 60%, preferably greater than 80%, more preferably greater than 90% of the final AKD product when isolated and analyzed using standard IR, SEC and NMR techniques.

[0036] Typical methods for separating AKD from the amine salts used by those skilled in the art generally employ one of three techniques: 1) solvent filtration of soluble AKD from the insoluble amine,salts, 2) centrifugation of the amine salts from the solvent solubilized AKD and 3) acid extraction of the amine salts from solvent solubilized AKD.

[0037] As the method described herein relies only upon the ability of the amine to act as a solvent and no additional solvent is added in the production of AKD, it is essentially a solventless method. The final AKD product produced by this method contains minimal amounts of solvent.

[0038] Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the various embodiments of the invention be limited to the specific values recited when defining a range. Moreover, all ranges set forth herein are intended to include not only the particular ranges specifically described, but also any combination of values therein, including the minimum and maximum values recited.

DESCRIPTION OF ANALYTICAL PROCEDURES

[0039] An infrared (IR) spectroscopy method is used for the determination of alkylketene dimer assay values. The alkylketene dimer sample is dissolved in heptane, extracted with a water/methanol mixture (to remove polar impurities that give a positive interference), and the IR spectrum scanned. The carbonyl absorbance, relative to the absorbance of standards similarly prepared, is used to quantitate the alkylketene dimer assay.

[0040] A size-exclusion chromatography (SEC) method is used for measuring the fraction of species higher in molecular weight than alkylketene dimer. The alkylketene dimer sample is dissolved in tetrahydrofuran (THF) and chromatographed at 40°C. A differential refractive index (DRI) detector is used. The alkylketene dimer elutes as a single peak. The area percent of the fraction higher in molecular weight is reported.

[0041] Nuclear magnetic resonance (NMR) spectroscopy is used to quantitate the byproducts and process impurities present in alkylketene dimer samples. The sample and internal standard, triphenylphosphine oxide (TPPO), are dissolved in d-chloroform, and the proton spectrum obtained. The impurities, other than those quantitated as described in [00036], are calculated on an absolute weight basis.

EXAMPLES

[0042] The embodiments of the present invention are further defined in the following Examples It should be understood that these Examples are given by way of illustration only. From the above discussion and these Examples, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various uses and conditions. Thus various, modifications of the present invention in addition to those shown and described herein will be apparent to those skilled in the art from the foregoing description. Although the invention has been described with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to the particulars disclosed, and extends to all equivalents within the scope of the claims.

[0043] Generally, in the Examples described herein, the reactor assemblies comprised a jacketed resin kettle having an internal capacity of 50 to 1000 milliliters. Each reactor assembly was equipped with a 4-neck kettle head and a Teflon® stopcock for draining the reactor contents. Each vessel was also equipped with a Teflon anchor controlled via an overhead stirrer, a cold water condenser with gas bubbler, a y-tube, thermocouple, nitrogen inlet, rubber septa and a stopper. The glassware was dried in an oven at 105°C for 1 to 2 hours and flushed with nitrogen overnight.

Example 1: 1.0/0.6 Mole Ratio Fatty Acid Chloride 364/N,N,N',N'-tetramethyl-1,6-hexanediamine

[0044] The vessel was charged with N,N,N',N'-tetramethyl-1,6-hexanediamine (12.1g, 70.22 mmol) and heated to 65°C with a water circulation bath while stirring and blanketing with nitrogen. Once an internal temperature of 65°C was achieved, the addition of fatty acid chloride 364 (34.7g 119.64 mmol) was started via syringe pump through one of the septa. The fatty acid chloride was added at an even rate over 40 minutes to maintain the reaction temperature between 60 and 65°C. Once the addition was complete, the hot water in the bath was replaced with ice water. The reaction slurry was treated with chilled 37.5% HCl (10.2g, 105 mmol) plus de-ionized water (29.7g). Once the temperature was cooled to 45°C the cold water bath was replaced with hot water to heat the reaction rapidly back to 90°C. Once the slurry was heated to 90°C for separation the crude reaction product was isolated and analyzed using standard IR, SEC and NMR techniques and data to determine that the alkyl ketene dimer assay was 94.0%.

Example 2: 1.0/0.6 Mole Ratio Fatty Acid Chloride 291/N,N,N',N'-tetramethyl-1,6-hexanediamine

[0045] To the vessel was charged N,N,N',N'-tetramethyl-1,6-hexanediamine (11.3g, 65.6 mmol) and heated to 65°C. Fatty acid chloride 291 (35.0g 115.7 mmol) was added at an even rate over 35 minutes. When the addition was complete, the hot water in the bath was replaced with ice water. 5 minutes after the fatty acid chloride was added, 37.5% HCl_(aq) (9.7g, 99 mmol) plus 27.6g of de-ionized water were combined, chilled and added to the reaction while cold water was circulated to cool it. When the temperature reached 45°C, the cold water in the bath was replaced with, hot water in order to heat the reaction to 90°C. Once the reaction reached 65°C the stirring was slowed to a minimum speed. Once the slurry was heated to 90°C for separation the crude reaction product was isolated and analyzed using standard IR, SEC and NMR techniques. It was determined that alkyl ketene dimer assay was 92.5%.

Example 3: 1.00/0.94 Mole Ratio Fatty Acid Chloride 532/N,N,N',N'-tetramethyl-1,6-hexanediamine

[0046] The reaction assembly was the same as stated above (Example 2) except that an addition funnel wrapped with heating tape was used to add the fatty acid chloride instead of a syringe pump. To the reaction vessel was charged tetramethyl-1,6-hexanediamine (15.9g, 92.3 mmol) and heated to 63°C with a water circulation bath. Once the tetramethyl-1,6-hexanediamine was at reaction temperature, liquid fatty acid chloride 532 (34.3g, 98.7 mmol), was charged over a period of 90 minutes. When the addition was complete, the hot water in the bath was replaced with ice and cold water. Six minutes after the addition was complete 37.5% HCl (13.4, 138 mmol) and cold de-ionized water (39.1g) was charged. When the temperature reached 35°C, the cold water in the bath was replaced with hot water in order to heat the reaction to 90°C. Once the slurry was heated to 90°C for separation, the crude reaction product was isolated and analyzed using standard IR, SEC and NMR techniques. It was determined that the alkyl ketene dimer assay was 88.1 %.

Example 4: 1.00/0.6 Mole Ratio Fatty Acid Chloride 364/N,N,N',N'-pentamethyldiethylenetriamine

[0047] The procedure for this reaction was the same as Example 1. To the reaction vessel, in a manner analogous to Example 1, was charged fatty acid chloride 364 (34.7g, 116.64 mmol), pentamethyldiethylenetriamine (12.3g, 70.98 mmol), 37.5% HCl (10.2g, 105 mmol) and de-ionized water (30.2g). Once the slurry was heated to 90°C for separation the crude reaction product was isolated and analyzed using standard IR, SEC and NMR techniques. It was determined that the alkyl ketene dimer assay was 85.5%.

Example 5: 1.0/0.95 Mole Ratio Fatty Acid Chloride 291/N,N,N',N",N"-pentamethyldiethylenetriamine

[0048] The procedure for this reaction was the same as Example 2. To the reaction vessel, in a manner analogous to Example 2, was charged fatty acid chloride 364 (30.0g, 99.2 mmol), pentamethyldiethylenetriamine (16.5g, 95.2 mmol), 37.5% HCl (13.7g, 141 mmol) and de-ionized water (40.8g). Once the slurry was heated to 90°C for separation, the crude reaction product was isolated and analyzed using standard IR, SEC and NMR techniques. It was determined that the alkyl ketene dimer assay was 80.2%.

Example 6: 1.0/0.6 Mole Ratio Fatty Acid Chloride 364/N,N,N',N",N"-pentamethyldipropylenetriamine

[0049] The procedure for this reaction was the same as Example 1. To the vessel, in a manner analogous to Example 1, was charged fatty acid chloride 364 (34.7g, 119.6mmol), pentamethyldiethylenetriamine (14.1g, 70.0 mmol), 37.5% HCl (10.2g, 105 mmol) and de-ionized water (36.3g). Once the slurry was heated to 90°C for separation the crude reaction product was isolated and analyzed using standard IR, SEC and NMR techniques. It was determined that the alkyl ketene dimer assay was 85.0%.

Example 7: 1.0/0.6 Mole Ratio Fatty Acid Chloride 291/N,N,N',N'-tetramethyl-1,3-propanediamine

[0050] The procedure for this reaction was the same as Example 2. To the vessel, in a manner analogous to Example 2, was charged fatty acid chloride 291 (35.0g, 115.73 mmol), tetramethyl-1,3-propanediamine (8.6g, 66.03 mmol), 37.5% HCl (9.6g, 99 mmol) and de-ionized water (18.8g). Once the slurry was heated to 90°C for separation the crude reaction product was isolated and analyzed using standard IR, SEC and NMR techniques. It was determined that the alkyl ketene dimer assay was 65.9%.

Example 8: 1.0/0.6 Mole Ratio Fatty Acid Chloride 364/tetraethylethylenediamine

[0051] The procedure for this reaction was the same as Example 1. To the reaction vessel, in a manner analogous to Example 1, was charged fatty acid chloride 364 (34.7g, 117 mmol), tetraethylethylenediamine (12.3g, 71.3 mmol), 37.5% HCl (10.2g, 105 mmol) and de-ionized water (30.4g). Once the slurry was heated to 90°C for separation the crude reaction product was isolated and analyzed using standard IR, SEC and NMR techniques. It was determined that the alkyl ketene dimer assay was 74.5%.

Claims

1. A process for the preparation of alkyl ketene dimers, comprising in sequence the steps of:

(a) charging a polyamines to a reaction vessel, and then heating the polyamine to a temperature ranging from 50°C to 70°C;

(b) charging a fatty acid chloride to the reaction vessel containing the polyamine over a time period ranging from 30-90 minutes, thereby forming a reaction mixture comprising an alkyl ketene dimer/amine salt;

(c) adding an amount of water to the reaction mixture wherein an organic alkyl ketene dimmer layer and an aqueous salt layer are formed;

(d) separating the organic alkyl ketene dimer layer and the aqueous salt layer,

wherein the polyamine used in the process is present in amounts ranging from 0.5 to less than 1.0
equivalents per mole equivalent of fatty acid chloride.

2. The process according to claim 1, wherein the polyamine of step (a) comprises a tertiary cyclic polyamine moieties containing polar functional groups, polyamine catalysts or straight-chain or branched tertiary polyamines.

3. The process according to claim 2, wherein the polyamine(s) are tertiary cyclic polyamine moieties containing polar functional groups.

4. The process according to claim 2, wherein the polyamines comprise cyclic polyamines.

5. The process according to claim 4, wherein the cyclic polyamine is 1,4-diazabicyclo[2.2.2]octane, 1,4-dimethyl piperazine or 4,4'-trimethylenebis(1-methyl-piperidine).

6. The process according to claim 2, wherein the straight-chain tertiary polyamines may be selected from the group consisting of 2,4-dimethyl-2,4-diazapentane, 2,5-dimethyl-2,5-diazahexane, 1,1'-(1,2-ethanediyl)bis[piperidine], N,N;N', N'-tetramethyl-1,2-diaminocyclohexane, 1,4-dimethyl-1,4-diazacyclchexane, diarabicyclo[2.2.2]octane, 2,6-dimethyl-2,6-diazaheptane, 2.7-dimethyl-2,7-diazaoctane, 2,7-dimethyl-2,7-diaza-4-octene, 2,7-dimethyl-2,7-diaza-4-octyne, 2,9-dimethyl-2,9-diazadecane, and 2,5,8,11-tetramethyl-2,5,8,11-tetraazadodecane.

7. The process according to claim 2, wherein the branched tertiary polyamines comprise N,N,N',N",N"',N"'-hexamethylethylenetetramine; N,N,N",N"-tetramethyl-1,6-hexanediamine; N,N,N',N"N"-pentamethyldiethylenetriamine; N,N,N",N"-tetramethyl-1,3-propanediamine; N,N,N",N"-tetraethylethylenediamine; N,N,N",N"-tetramethylethylenediamine and N,N,N"',N"-tetramethylmethylenediamine. Preferred examples include N,N,N",N"-tetramethyl-1,6-hexanediamine; N,N,N',N"N"-pentamethyldiethylenetriamine; N,N,N",N"-tetramethyl-1,3-propanediamine; or N,N,N",N"-tetraethylethylenediamine.

8. The process according to claim 1, wherein the fatty acid chloride comprises stearoyl chloride.

9. The process according to claim 1, wherein the polyamine comprises 1,4-dimethyl piperazine and the fatty acid chloride is stearoyl chloride.

10. The process according to claim 1, where in step (a) the temperature ranges from 50°C to 65°C.

11. The process according to claim 10, where in step (a) the temperature ranges from 55°C to 65°C.

12. The Process according to claim 11, where in step (a) the temperature is 65°C.

13. The process according to claim 1, wherein the fatty acid chloride is charged to the reaction vessel over a time period ranging from 35 to 40 minutes.

14. The process according to claim 13, wherein the fatty acid chloride is charged to the reaction vessel over a time period of 40 minutes.

Ansprüche

1. Verfahren zur Herstellung von Alkylketendimeren, umfassend die Schritte in der folgenden Reihenfolge:

(a) Laden eines Polyamins zu einem Reaktionsbehälter und anschließendes Erwärmen des Polyamins auf eine Temperatur im Bereich von 50 bis 70°C,

(b) Laden eines Fettsäurechlorides zum Reaktionsbehälter, umfassend das Polyamin, über eine Zeitperiode im Bereich von 30 bis 90 Minuten, unter Bildung einer Reaktionsmischung, umfassend ein Alkylketendimer/Aminsalz;

(c) Zugabe einer Menge an Wasser zur Reaktionsmischung, worin eine organische Alkylketendimerschicht und eine wässrige Salzschicht gebildet werden;

(d) Trennen der organischen Alkylketendimerschicht und der wässrigken Salzschicht,

worin das Polyamin, das im Verfahren verwendet wird, in Mengen im Bereich von 0,5 bis weniger als 1,0 Äquivalenten pro Moläquivalent des Fettsäurechlorides vorhanden ist.

2. Verfahren nach Anspruch 1, worin das Polyamin von Schritt (a) einen tertiären cyclischen Polyaminanteil, umfassend polare funktionelle Gruppen, Polyaminkatalysatoren oder geradkettige oder verzweigte tertiäre Polyamine umfasst.

3. Verfahren nach Anspruch 2, worin das/die Polamin(e) tertiäre cyclische Polyaminanteile sind, umfassend polare funktionelle Gruppen.

4. Verfahren nach Anspruch 2, worin die Polamine cyclische Polyamine umfassen.

5. Verfahren nach Anspruch 4, worin das cyclische Polyamin 1,4-Diazabicyclo[2.2.2]octan, 1,4-Dimethylpiperazin oder 4,4'-Trimethylenbis(1-methyl-piperidin) ist.

6. Verfahren nach Anspruch 2, worin die geradkettigen tertiären Polyamine aus der Gruppe ausgewählt sein können, bestehend aus 2,4-Dimethyl-2,4-diazapentan, 2,5-Dimethyl-2,5-diazahexan, 1,1'-(1,2-Ethandiyl)bis[piperidin], N,N,N',N'-Tetramethyl-1,2-diaminocyclohexan, 1,4-Dimethyl-1,4-diazacyclohexan, Diazabicyclo[2.2.2]octan, 2,6-Dimethyl-2,6-diazaheptan, 2,7-Dimethyl-2,7-diazaoctan, 2,7-Dimethyl-2,7-diaza-4-octen, 2,7-Dimethyl-2,7-diaza-4-octin, 2,9-Dimethyl-2,9-diazadecan und 2,5,8,11-Tetramethyl-2,5,8,11-tetraazadodecan.

7. Verfahren nach Anspruch 2, worin die verzweigten tertiären Polyamine umfassen: N,N,N',N",N"',N"'-Hexamethylethylentetramin; N,N,N",N"-Tetramethyl-1,6-hexandiamin; N,N,N',N",N"-Pentamethyldiethylentriamin; N,N,N",N"-Tetramethyl-1,3-propandiamin; N,N,N",N"-Tetraethylethylendiamin; N,N,N",N"-Tetramethylethylendiamin und N,N,N",N"-Tetramethylmethylendiamin, wobei bevorzugte Beispiele umfassen N,N,N",N"-Tetramethyl-1,6-hexandiamin; N,N,N',N",N"-Pentamethyldiethylentriamin; N,N,N",N"-Tetramethyl-1,3-propandiamin oder N,N,N",N"-Tetraethylethylendiamin.

8. Verfahren nach Anspruch 1, worin das Fettsäurechlorid Stearoylchlorid umfasst.

9. Verfahren nach Anspruch 1, worin das Polyamin 1,4-Dimethylpiperazin umfasst und das Fettsäurechlorid Stearoylchlorid ist.

10. Verfahren nach Anspruch 1, worin im Schritt (a) die Temperatur im Bereich von 50 bis 65°C liegt.

11. Verfahren nach Anspruch 10, worin im Schritt (a) die Temperatur im Bereich von 55 bis 65°C liegt.

12. Verfahren nach Anspruch 11, worin im Schritt (a) die Temperatur 65°C ist.

13. Verfahren nach Anspruch 1, worin das Fettsäurechlorid zum Reaktionsbehälter über eine Zeitperiode im Bereich von 35 bis 40 Minuten geladen wird.

14. Verfahren nach Anspruch 13, worin das Fettsäurechlorid zum Reaktionsbehälter über eine Zeitperiode von 40 Minuten geladen wird.

Revendications

1. Procédé pour la préparation de dimères d'alkylcétènes, comprenant de manière successive les étapes consistant à:

(a) introduire une polyamine dans un récipient de réaction, puis à chauffer la polyamine à une température allant de 50°C à 70°C;

(b) introduire un chlorure d'acide gras dans le récipient de réaction contenant la polyamine en une période de temps allant de 30 à 90 minutes, en formant ainsi un mélange réactionnel comprenant un dimère d'alkylcétène/sel d'amine;

(c) ajouter une quantité d'eau au mélange réactionnel dans lequel sont formées une phase organique de dimère d'alkylcétène et une phase aqueuse de sel ;

(d) séparer la phase organique de dimère d'alkylcétène et la phase aqueuse de sel,
dans lequel la polyamine utilisée dans le procédé est présente en des quantités allant de 0,5 à moins de 1,0 équivalent par équivalent molaire de chlorure d'acide gras.

2. Procédé suivant la revendication 1, dans lequel la polyamine de l'étape (a) comprend des groupements polyamine cycliques tertiaires contenant des groupes fonctionnels polaires, des catalyseurs du type polyamine ou des polyamines tertiaires à chaîne droite ou ramifiée.

3. Procédé suivant la revendication 2, dans lequel la ou les polyamines sont des groupements polyamine cycliques tertiaires contenant des groupes fonctionnels polaires.

4. Procédé suivant la revendication 2, dans lequel les polyamines comprennent des polyamines cycliques.

5. Procédé suivant la revendication 4, dans lequel la polyamine cyclique est le 1,4-diazabicyclo[2.2.2]octane, la 1,4-diméthylpipérazine ou la 4,4'-triméthylènebis(1-méthyl-pipéridine).

6. Procédé suivant la revendication 2, dans lequel les polyamines tertiaires à chaîne droite peuvent être choisies dans le groupe consistant en le 2,4-diméthyl-2,4-diazapentane, le 2,5-diméthyl-2,4-diazahexane, la 1,1'-(1,2-éthanediyl)bis[pipéridine], le N,N,N',N'-tétraméthyl-1,2-diaminocyclohexane, le 1,4-diméthyl-1,4-diazacyclohexane, le diazabicyclo[2.2.2]octane, le 2,6-diméthyl-2,6-diazaheptane, le 2,7-diméthyl-2,7-diazaoctane, le 2,7-diméthyl-2,7-diaza-4-octène, le 2,7-diméthyl-2,7-diaza-4-octyne, le 2,9-diméthyl-2,9-diazadécane et le 2,5,8,11-tétraméthyl-2,5,8,11-tétra-azadodécane.

7. Procédé suivant la revendication 2, dans lequel les polyamines tertiaires ramifiées comprennent la N,N,N',N",N"',N"'-hexaméthyléthylènetétramine, la N,N,N',N''-tétraméthyl-1,6-hexanediamine, la N,N,N',N'',N''-pentaméthyl-diéthylènetriamine, la N,N,N",N"-tétraméthyl-1,3-propanediamine, la N,N,N",N"-tétraéthyléthylènediamine, la N,N,N",N"-tétraméthyléthylènediamine et la N,N,N",N"-tétraméthyl-méthylènediamine, les exemples préférés comprenant la N,N,N",N"-tétraméthyl-1,6-hexanediamine, la N,N,N',N",N"-pentaméthyldiéthylènetriamine, la N,N,N",N"-tétraméthyl-1,3-propanediamine et la N,N,N",N"-tétraéthyléthylène-diamine.

8. Procédé suivant la revendication 1, dans lequel le chlorure d'acide gras comprend le chlorure de stéaroyle.

9. Procédé suivant la revendication 1, dans lequel la polyamine comprend la 1,4-diméthylpipérazine et le chlorure d'acide gras est le chlorure de stéaroyle.

10. Procédé suivant la revendication 1, dans lequel, dans l'étape (a), la température va de 50°C à 65°C.

11. Procédé suivant la revendication 10, dans lequel, dans l'étape (a), la température va de 55°C à 65°C.

12. Procédé suivant la revendication 11, dans lequel, dans l'étape (a), la température est égale à 65°C.

13. Procédé suivant la revendication 1, dans lequel le chlorure d'acide gras est introduit dans le récipient de réaction en un temps de 35 à 40 minutes.

14. Procédé suivant la revendication 13, dans lequel le chlorure d'acide gras est introduit dans le récipient de réaction en un temps de 40 minutes.